Flat wire to round wire connection system

Abstract

An electrical connector forms a permanent electrical connection between a flat cable having multiple conductors and a plurality of round wires. The connector comprises a first connector half and a second connector half. The first connector half has a flat cable channel and at least one flat cable access window in communication with the flat cable channel. The second connector half has a plurality of wire channels for receiving round wires, and at least one wire access window in communication with one of the wire channels. Each cable access window is aligned with at least one wire access window to facilitate a permanent connection between a conducting strip of the multiple conductor flat cable and a conducting core of the round wire.

We claim:  
     
       1. A connector for creating a permanent electrical connection, comprising: 
       a first connector half having a flat cable channel for receiving a multiple conductor flat cable;  
       at least one flat cable access window disposed within the first connector half in communication with the flat cable channel;  
       a second connector half having a plurality of wire channels, each of the wire channels for receiving a round wire; and  
       at least one wire access window disposed within the second connector half in communication with at least one of the wire channels, the at least one flat cable access window being aligned with the at least one wire access window to facilitate a permanent connection between a conducting strip of a multiple conductor flat cable and a conducting core of said round wire when the first connector half is operatively aligned with the second connector half.  
     
     
       2. The connector as in claim  1 , further comprising at least two locating pins extending from the first connector half for locating and strain relieving a multiple conductor flat cable. 
     
     
       3. The connector as in claim  2 , further comprising at least two pilot holes disposed within the second connector half for receiving the locating pins to align the first connector half with the second connector half. 
     
     
       4. The connector as in claim  1 , wherein said conducting core of the round wire received in said each of the wire channels is registered with said conducting strip of the multiple conductor flat cable received in the flat cable channel. 
     
     
       5. The connector as in claim  1 , further comprising a wire-locating stop disposed within each of the wire channels for positioning said round wire. 
     
     
       6. The connector as in claim  1 , further comprising a wire retainer disposed within each of the wire channels for maintaining the position of said round wire during assembly. 
     
     
       7. The connector as in claim  1 , further comprising a strain relief rib disposed within said first connector half to prevent damage to the electrical connection. 
     
     
       8. The connector as in claim  1 , further comprising an interior lock arm extending from the first connector half for engaging a lock tab disposed within said second connector half, whereby said first connector half and said second connector half are prevented from bowing. 
     
     
       9. The connector as in claim  1 , further comprising at least one pair of lateral retainer tabs extending inwardly from side walls of the first connector half, a pair of retainer rails extending outwardly from side walls of the second connector half, each of the retainer tabs snapping one of the pair of retainer rails to fasten the first connector half and the second connector half together. 
     
     
       10. The connector as in claim  1 , wherein the permanent connection is achieved by sonic welding. 
     
     
       11. The connector as in claim  1 , wherein the permanent connection is achieved by laser welding. 
     
     
       12. A connector for creating a permanent electrical connection, comprising: 
       a first connector half having a flat cable channel receiving a multiple conductor flat cable having a plurality of conducting strips;  
       a plurality of cable access windows disposed within the first connector half, the plurality of cable access windows being in communication with the flat cable channel, each of the plurality of cable access windows being in registration with one of the plurality of conducting strips;  
       a second connector half including a plurality of wire channels for receiving a plurality of round wires; and  
       a plurality of wire access windows disposed within the second connector half, each of the plurality of wire access windows being in communication with one of the plurality of wire channels and aligned with one of the plurality of cable access windows to facilitate a permanent connection between the conducting strips of the multiple conductor flat cable and conducting cores of the plurality of round wires when the first connector half is operatively aligned with the second connector half.  
     
     
       13. The connector of claim  12 , further comprising at least two locating pins extending from the firs t connector half for locating and strain relieving the multiple conductor flat cable. 
     
     
       14. The connector of claim  13 , further comprising at least two pilot holes disposed within the second connector half for receiving the locating pins to position the first connector half with the second connector half. 
     
     
       15. The connector as in claim  12 , wherein the conducting cores are registered with respective ones of the plurality conducting strips of the multiple conductor flat cable. 
     
     
       16. The connector as in claim  12 , further comprising wire-locating stops disposed within the wire channels for positioning the plurality of round wires within the wire channels. 
     
     
       17. The connector as in claim  12 , further comprising wire retainers disposed within the wire channels for maintaining the position of the plurality of round wires during assembly. 
     
     
       18. The connector as in claim  12 , further comprising a strain relief rib disposed within the first connector half to prevent damage to the electrical connection. 
     
     
       19. The connector as in claim  12 , further comprising an interior lock arm extending from said first connector half and engaging a lock tab disposed within said second connector half, whereby the first connector half and the second connector half are prevented from bowing. 
     
     
       20. The connector as in claim  12 , further comprising at least one pair of lateral retainer tabs extending inwardly from side walls of the first connector half, a pair of retainer rails extending outwardly from side walls of the second connector half, each of the retainer tabs snapping one of the pair of retainer rails to fasten the first connector half and the second connector half together.